Leica iCONgrade iCP32 User Manual
Contents
1. MJB1300 Junction Box 20 to 60 30 to 70 MPM700 Electric Mast 20 to 60 30 to 70 MLS700 Laser Receiver 20 to 60 30 to 70 MUS1300 Tri Sonic 20 to 65 40 to 85 SP14 SP Sensor 20 to 60 40 to 80 MSS1300 Cross Slope Sensor 20 to 60 40 to 80 MRS1300 Rotation Sensor 20 to 60 40 to 80 79 iCONgrade Technical Data Protection against water dust and sand 80 Type Protection iCP32 Control Panel IP67 MMB1300 Cradle IP54 MJB1301 Junction Box IP67 MJB1300 Junction Box IP67 MPM700 Electric Mast IP45 MLS700 Laser Receiver IP68 MUS1300 Tri Sonic IP54 SP14 SP Sensor IP68 MSS1300 Cross Slope Sensor IP68 MRS1300 Rotation Sensor IP67 Humidity Type Protection iCP32 Control Panel Max 95 non condensing The effects of condensation are to be effectively counter acted by periodically drying out the instrument 5 2 Conformity to National Regulations Conformity to national regulations C Hereby Leica Geosystems AG declares that the iCP32 control panel is in compliance with the essential requirements and other relevant provisions of the applicable European Directives For the declaration of conformity please contact your Leica Geosystems distributor iCONgrade Technical Data 81 iCONgrade International Limited Warranty Software License Agreement 82 6 International Limited Warranty Software License Agreement Inter2. 300 m radius Sensor pick up range 18 5 cm Laser requirement All Rotating Lasers visible HeNe invisible Infrared diodes Laser Pulsed display 5 pulses per second 77 iCONgrade Technical Data MSS1300 Cross Slope Sensor SP14 Sensor 78 Parameter Specification Voltage range 24 V DC nom Nominal voltage 24 V DC Range 10 V 30 V Power consumption lt 0 25A Dimensions 15 3 x 8 7 x 3 9 cm Weight 0 855 kg Accuracy cross slope 0 1 slope at 25 Working range 80 Interfaces CAN MIL Parameter Specification Voltage range 24 V DC nom Nominal voltage 24 V DC Range 10 V 30 V Power consumption lt 0 25A Dimensions 15 3 x 8 7 x 3 9 cm Weight 0 855 kg Accuracy cross slope 0 1 slope at 25 Working range 80 Interfaces CAN MIL MRS1300 Rotation Sensor Environmental specifications iCONgrade Technical Data Parameter Specification Voltage range 24 V DC nom Nominal voltage 24 V DC Range 10 V 30 V Power consumption lt 0 25A Dimensions Q16 0 x 22 6 x 5 9 cm Weight 1 56 kg Working range 0 360 Temperature Type Operating temperature C Storage temperature C iCP32 Control Panel 20 to 60 30 to 70 MMB1300 Cradle 20 to 60 30 to 70 MJB1301 Junction Box 20 to 60 30 to 70
3. Where possible run with the slope sensor trailing not leading 17 iCONgrade Operation 2 1 2 Mast orientation 18 Mast orientation For Dozers and Graders without mast slope sensor you must make sure that the mast is at the as measured position that is the position the mast or masts were in during the mast measure up On a Dozer this means that the mast should not be mechanically sloped If for some reason the mast is actually mechanically sloped a new mast measure up must be done On a Grader the blade should be tipped back towards its end stop if that was the original measure position 2 1 3 No Articulation circle center shift or wheel lean on Grader Articulation circle For Grader systems that rely on the cross slope sensor and a single elevation sensor you Centershift and wheel must make sure that the machine is not articulated and that there is no side shift applied lean to the circle The front wheels must be upright not leaned Okay Articulated iCONgrade Operation 19 iCONgrade Operation 20 Circle center shifted Wheel leaned Wheel lean introduces an error in the reading from the mainfall sensor Articulation and circle Centershift introduce unmeasured blade rotation Operating with wheel lean circle centershift or articulation can cause inaccuracy in the cross slope being cut 2 1 4 Blade cushioning off iCONgrade Operation Grader blade cushioning off Usin
4. be inversed The SWAP function can also be activated by pressing the up key on both external multi switches simultaneously Requirements Two Tri Sonic sensors must be connected and the system must be in Grader mode 1 Move the Grader to a flat level ground 2 Set the moldboard level with the machine 3 Select slope on left side and sonic on right side Choose ground mode for the Tri Sonic 4 Manually set the cross slope of the blade to level 5 Set the height for the right sonic by pressing and holding F4 SEEK for 2 sec 6 Press F2 SWAP and the sensors will switch sides 7 Set the height for the left sonic by pressing and holding Ft SEEK for 2 sec The machine is now ready for the final grade following the previously pass 37 iCONgrade Operation 38 cE It is possible to have different heights and mode settings for the two Tri Sonic sensors 2 5 Laser Sensor Laser Sensor and manual mast iCONgrade Operation Using the Laser Sensor The Laser Sensor is used to measure the elevation of the blade This is done by measuring the distance from where the laser beam is hitting the laser and the centerline on the Laser Sensor When the Laser Sensor detects a laser beam this is indicated on the display by a red line through the laser icon If at some point the laser beam is lost while the control panel is set in auto mode it will give a beep and a red cross will appear with a text message saying
5. corner of the display and by an icon shown on the blade in relation to the actual placement of the sensor Example b 0 0 1 04 a Laser indication b Cross Slope A cross slope is selected in the right side and in the left side a Laser Sensor is selected 25 iCONgrade Operation iCONgrade Operation 2 3 Inspection Manual mode Seek mode 26 Setting a Reference Height When a sensor is selected the control panel automatically uses the last set reference height for that sensor There are two ways to change the reference e Manual mode e Seek mode Use the A Ly keys to change the reference height up or down Press the A and Lv keys simultaneously to enter the seek mode In seek mode the screen shows the current sensor value of the selected sensor Pressing both keys simultaneously again exits the seek mode Or press or F4 for seek mode z While in Seek Mode the height values at the top of the a 0 0 1 04 screen will be green o 1 2 CS gt If both keys are pressed and held for more than three seconds the control panel will take the current i sensor value and store as the new reference height 7 While holding these buttons the key will change o M from Seek to 0 0 Once the new reference height has been set the height values at the top of the screen will Seek Swap Reset Seek change back to black Automatic detection of the laser beam iCONgrade
6. knob on the bracket tilt the bracket and tighten the knob again iCONgrade Operation 33 iCONgrade Operation A caution 2 4 2 iCP32 system flexibility Mount the Tri Sonic Sensing range 34 System Components can protrude from the machine which could lead to bodily injury and or product damage Precautions Exercise caution in operation to avoid striking any objects or persons near the working area Operation with the Tri Sonic Sensor Multifunctional and multitask iCP32 system can be operated in various combinations for the most demanding job requirements Mount the Tri Sonic to the appropriate height for its maximum performance according to the reference used The sensing range shows the mimimum and maximum values possible wherever it can be achieved to obtain the range of best perfomance Reference Sensing Range Best Performance String 15 36 inch 38 91 cm 24 inch 60 cm Edge 15 36 inch 38 91 cm 24 inch 60 cm Flat Ground 15 99 inch 38 250 cm 24 inch 60 cm Reference ground Reference stringline iCONgrade Operation a Side View b Ground a Side View b String 35 iCONgrade Operation Reference edge Setting up the Tri Sonic 36 a Side View b Edge When setting the Tri Sonic sensor over a ref
7. modes Once selected press the lt key Following screens will appear by pressing the up AS or down yy Enter key to toggle between the screens iCONgrade Operation 29 iCONgrade Operation 30 C 4 C Tri Sonic Tri Sonic Tri Sonic Tri Sonic Tr i Sonic Tr i Sonic 2s Revert Eese Esc 2s Revert Esc Stringline describes the window where the Tri Sonic will work within certain range All readings outside of this range will be ignored Sideshift works only with the Edge and Stringline modes Go to the Sideshift menu option and set it to Yes Press both and keys simultaneously to set the control panel in seek mode Check that the height is approximately 60 cm Press both and keys simultaneously or press seek function key and keep them pressed for three seconds to set the reference height 10 Press the right key to set the machine in Auto Mode OO CON O 11 Press the Side A M function key to enable the automatic sideshift control LO 1 0 4 Cauro gt raurosa auro ne 0 0 a Seek Swap SSAM Seek iCONgrade Operation 31 iCONgrade Operation 2 4 1 Mounting the Tri Sonic Sensor er The direction of move ment of the Tri Sonic sensor 32 Installation and Set Up Tri Sonic Sensor The Tri Sonic can be installed quickly and easily with the simplest of tools Mount a support in a suitable location that is adjustable
8. A max Labelling SP14 SP Sensor icP32_015 TYPE SP 14 P N 782749 S N XXXXXXXX eca Leica Geosystems AG CH 9435 Heerbrugg Made in Denmark 20XX CER Power 12 24 V DC 6A max iCONgrade Safety Directions 73 iCONgrade Technical Data 5 5 1 ee iCP32 Control Panel MMB1300 Cradle 74 Technical Data iCP32 Technical Data The iCP32 system is designed to operate from standard vehicle power systems at 24V DC check to ensure proper connection and polarity Parameter Specification Power Supply The iCP32 is supplied from the cradle MMB1300 Power consumption lt 200 mA Graphic display 4 LCD colour screen Keypad 18 keys with backlight Interfaces Infrared Dimensions 12 5 x 18 0 x 3 7 cm Weight 0 5 kg Parameter Specification Voltage range 24 V DC nom Dimensions 12 4 x 15 2 x 4 4 cm Weight 0 320 kg Communication Infrared 1 Mbit Output 2 x RS232 RX TX 12V 2Amp GND 2 x CAN and J1939 MJB1300 and MJB1301 Junction Box iCONgrade Technical Data Parameter Specification Voltage range Power consumption 24 V DC nom Nominal voltage 24 V DC Range 10 V 30 V lt 0 5 A with no sensors and valve connected Dimensions MJB1300 13 8 x 18 3 x 6 4cm MJB1301 14 5 x 18 3 x 6 4cm Weight 2 kg Hydraulic Output Settings Proportional valves On Off and Danfoss Inter
9. Leica iCONgrade iCP32 User Manual Version 1 0 English when it has to be right eca Geosystems iCONgrade Introduction Introduction AW Product identification Congratulations on your purchase of iCONgrade machine control system iCONgrade System is an ideal tool for increasing productivity in all aspects of the construction earthmoving industry This manual contains important safety directions as well as instructions for setting up the system and operating it Refer to the chapter 4 Safety Directions for further information Read carefully through the User Manual before you switch on the product To ensure safety when using the system please also observe the directions and instructions contained in the User Manual and Safety Handbook issued by the e Machine manufacturer The type and serial number of your products are indicated on the label on the base of the unit Enter the model and serial number in your manual and always refer to this information when you need to contact your agency or Leica Geosystems authorised service workshop Type iCP32 Control Box Serial No Type MMB1300 Cradle Serial No F Symbols The symbols used in this manual have the following meanings Type Description A Danger Indicates an imminently hazardous situation which if not avoided will result in death or serious injury A Warning Indicates a potentially hazardous situation or an uninten
10. Operation For systems with a MPM700 Electric Mast entering seek mode will start an automatic search for the laser beam If the laser sensor is out of beam the operator can select in which direction the mast should start moving to look for the laser beam using the and keys The mast will then start moving in that direction until the laser sensor has the beam centered If the mast during a seek reaches Its top or bottom limit it will automatically switch moving direction and continue to seek for the laser beam until it is found or it hits the next end point 27 iCONgrade Operation 28 2 4 Using the MUS1300 Tri Sonic Sensor Using Tri Sonics The Tri Sonic can also measure the horizontal distance to a stringline and therefore it can be used to control the sideshift on a grader To do that complete the following steps 1 Place the machine so that the Tri Sonic is above ground the edge or stringline The sensor needs an edge or string to follow before it can control the sideshift 2 Move the blade to the working position 3 Move the Tri Sonic to a good working height This is approximately 60 cm above the reference 4 Select the Tri Sonic on the same side as where it is placed on the machine 5 Enter the Tri Sonic menu First press the Z key then press the Adjust function key 1 0 4 Select between the different modes e Ground Mode e Edge Mode e Stringline Press the or key to toggle between the
11. Wild Strasse CH 9435 Heerbrugg e Switzerland when it has to be right etca Phone 41 71 727 31 31 www leica geosystems com Geosystems
12. ain injury Precautions When setting up the product make sure that the accessories for example tripod tribrach connecting cables are correctly adapted fitted secured and locked in position Avoid subjecting the product to mechanical stress A Warning If the product is improperly disposed of the following can happen e If polymer parts are burnt poisonous gas are produced which may impair health e If batteries are damaged or are heated strongly they can explode and cause poisoning burning corrosion or environmental contamination e By disposing of the product irresponsibly you may enable unauthorized persons to use it in contravention of the regulations exposing themselves and third parties to the risk of severe injury and rendering the environment liable to contamination Precautions The product must not be disposed with household waste Dispose of the product appropriately in accordance with the national regulations in force in your country Always prevent access to the product by unauthorised personnel Product specific treatment and waste management information can be received from your Leica Geosystems dealer iCONgrade Safety Directions 65 iCONgrade Safety Directions 66 4 6 Description A Warning A caution Electromagnetic Compatibility EMC The term Electromagnetic Compatability is taken to mean the capability of the product to function smoothly in an environment where electromagnetic ra
13. ained under these conditions If the product is operated with connecting cables attached at only one of their two ends for example external supply cables interface cables the permitted level of electromagnetic radiation may be exceeded and the correct functioning of other products may be impaired Precautions While the product is in use connecting cables for example product to external battery product to computer must be connected at both ends iCONgrade Safety Directions 67 iCONgrade Safety Directions 4 7 Labelling 68 Labelling iCP32 Control Panel icP32_007 iCP32 Grading 2D Panel P N 798669 S N XXXXXXXX e feica Leica Geosystems AG CH 9435 Heerbrugg Made in Denmark 20XX CE ower 12 24 V DC 6A max Labelling MMB1300 Cradle icP41_009 TYPE MMB1300 P N 764910 S N XXXXXXXX Leica Leica Geosystems AG CH 9435 Heerbrugg Made in Denmark 20XX CER ower 12 24 V DC 6A max Labelling MJB1300 Junction Box Labelling MJB1301 Junction Box icP32_008 TYPE MJB1300 P N 764838 S N XXXXXXXX e Leica Leica Geosystems AG CH 9435 Heerbrugg Made in Denmark 20XX CE ower 12 24 V DC 6A max icP32_009 TYPE MJB1301 P N 764839 S N XXXXXXXX e Leica Leica Geosystems AG CH 9435 Heerbrugg Made in Denmark 20XX ce 12 24 V DC 6A max iCONgrade Safety Directions 69 iCONgrade Safety Directi
14. cate which sensor is currently in use select AUTO If not then select either TRACKER or GPS from the menu Once Auto GPS Tracker is selected it is required to EXIT from this menu for the change to take effect and then re enter the menu to adjust gains Gains need to be set for both GPS or Tracker depending on which sensor is used If AUTO is selected the iCP32 will use the gains set in the Tracker and GPS settings Use the right arrow key to enter the gains settings Refer to chapter 2 8 Setting the Value for Gain and Deadband for configuring Gains iCONgrade Operation 44 To select 3D Slope Press the left or right sensor key once and then press the Adjust function key to enter the adjust menu Note that it s only the current selected sensor in either left or right side that is adjusted Set gains for 3D Slope as explained in chapter 2 8 Setting the Value for Gain and Dead band 2 8 Adjust the gain and deadband Deadband er iCONgrade Operation Setting the Value for Gain and Deadband To adjust the gain and deadband of each of the sensors complete the following steps 1 Press the left or right key once and then press the Adjust function key to enter the adjust menu Note that it s only the current selected sensor in either left or right side that is adjusted 2 Use the or key to scroll through the settings 3 Use the or key to change the value 4 To exit the adjust menu press the men
15. cipate and avoid operational hazards The person responsible for the product must ensure that all users understand these instruc tions and adhere to them Intended Use e Determine the position of a dozer grader blade or excavator bucket e Calculate the distance between the blade bucket and a reference model surface line or point e Automatic adjustment of a dozer grader hydraulic system in order to match the blade to the reference model e Use of the product without instruction e Use outside of the intended limits e Disabling safety systems e Removal of hazard notices e Opening the product using tools for example screwdriver unless this is specifically permitted for certain functions e Modification or conversion of the product e Use after misappropriation e Use of products with obviously recognizable damages or defects e Use with accessories from other manufacturers without the prior explicit approval of Leica Geosystems A Warning A Warning 4 3 Environment AN Danger 4 4 Manufacturer of the product e Inadequate safeguards at the work site for example working on roads e Controlling of machines moving objects or similar monitoring application without addi tional control and safety installations Adverse use can lead to injury malfunction and damage It is the task of the person responsible for the equipment to inform the user about hazards and how to counteract them The pro
16. d downloaded at the Leica Geosystems home page at http www leica geosystems com swilli cense or collected from your Leica Geosystems distributor You must not install or use the software unless you have read and accepted the terms and conditions of the Leica Geosystems Software License Agreement Installation or use of the software or any part thereof is deemed to be an acceptance of all the terms and conditions of such License Agreement If you do not agree to all or some of the terms of such License Agreement you may not download install or use the software and you must return the unused software together with its accompanying documentation and the purchase receipt to the dealer from whom you purchased the product within ten 10 days of purchase to obtain a full refund of the purchase price iCONgrade International Limited Warranty Software License Agreement 83 Total Quality Management Our commitment to total customer satisfaction 5 E ot Leica Geosystems AG Heerbrugg Switzerland has been ro E certified as being equipped with a quality system which meets as the International Standards of Quality Management and Quality Systems ISO standard 9001 and Environmental Management a ISO 9001 1SO 14001 Systems ISO standard 14001 w N Ask your local Leica Geosystems dealer for more information about our TQM program Printed in Switzerland 2012 Leica Geosystems AG Heerbrugg Switzerland Leica Geosystems AG Heinrich
17. ded use which if not avoided could result in death or serious injury A Caution Indicates a potentially hazardous situation or an unintended use which if not avoided may result in minor or moderate injury and or appreciable material financial and environmental damage er Important paragraphs which must be adhered to in practice as they enable the product to be used in a technically correct and efficient manner Validity of this manual This manual applies to the Control Box iCP32 and the 2D part of the Control Box iCP42 iCONgrade Introduction iCONgrade Table of Contents Table of Contents In this manual Topic Page 1 Product Overview 6 1 1 Product Description and Features 6 1 2 Getting Started 11 1 3 Sensor Setup Keys 13 2 Operation 16 2 1 Pre power up checks 16 2 1 1 Best operation practice for Grader Systems 17 2 1 2 Mast orientation 18 2 1 3 No Articulation circle center shift or wheel lean on Grader 19 2 1 4 Grader blade cushioning off 21 2 1 5 No blade rotation on Dozer 22 2 2 Select the Input Source 23 2 3 Setting a Reference Height 26 2 4 Using the MUS1300 Tri Sonic Sensor 28 2 4 1 Installation and Set Up Tri Sonic Sensor 32 2 4 2 Operation with the Tri Sonic Sensor 34 2 4 3 Swap Function 37 2 5 Using the Laser Sensor 39 2 6 SP14 Sensor 4l 2 7 3D Sensors 43 2 8 Setting the Value for Gain and Deadband 45 2 9 Sensor Calibration Wizard 48 2 10 Mach
18. diation and electrostatic discharges are present and without causing electromagnetic distur bances to other equip ment Electromagnetic radiation can cause disturbances in other equipment Although the product meets the strict regulations and standards which are in force in this respect Leica Geosystems cannot completely exclude the possibility that other equipment may be disturbed There is a risk that disturbances may be caused in other equipment if the product is used in conjunction with accessories from other manufacturers for example field computers personal computers two way radios non standard cables or external batteries Precautions Use only the equipment and accessories recommended by Leica Geosystems When combined with the product they meet the strict requirements stipulated by the guide lines and standards When using computers and two way radios pay attention to the infor mation about electromagnetic compatibility provided by the manufacturer A caution A Warning Disturbances caused by electromagnetic radiation can result in erroneous measurements Although the product meets the strict regulations and standards which are in force in this respect Leica Geosystems cannot completely exclude the possibility that the product may be disturbed by very intense electromagnetic radiation for example near radio transmitters two way radios or diesel generators Precautions Check the plausibility of results obt
19. duct is not to be operated until the user has been instructed on how to work with it Unauthorized modification of building and constructions machines by mounting or installing the product may alter the function and safety of the machine Precautions Follow the instructions of the machine manufacturer If no appropriate instruction is avail able ask machine manufacturer for instructions before mounting or installing the product Limits of Use Suitable for use in an atmosphere appropriate for permanent human habitation not suitable for use in aggressive or explosive environments Local safety authorities and safety experts must be contacted before working in hazardous areas or in close proximity to electrical installations or similar situations by the person in charge of the product Responsibilities Leica Geosystems AG hereinafter referred to as Leica Geosystems is responsible for supplying the product including the user manual and original accessories in a completely safe condition iCONgrade Safety Directions 61 iCONgrade Safety Directions 62 Manufacturers of non Leica Geosystems accessories Person in charge of the product A Warning A Warning A Warning 4 5 A Warning The manufacturers of non Leica Geosystems accessories for the product are responsible for developing implementing and communicating safety concepts for their products and are also responsible for the effectiveness of th
20. e steering if machine is defective like after a crash or other damaging events or alterations to the machine Precautions Periodically perform control measurements and field adjustments on the machine as speci fied in the User Manual While working construction and grading should be checked by appropriate means for example spirit level tachymeter before and after important meas uring tasks While steering or navigating the machine accidents may occur due to a the operator not paying attention to the surroundings persons ditches traffic etc or b malfunctions of a system component interference etc Precautions The operator assures that the machine is operated guided and monitored by a qualified user e g driver The user has to be able to take emergency measures for example an emergency stop The absence of instruction or the inadequate imparting of instruction can lead to incorrect or adverse use and can give rise to accidents with far reaching human material financial and environmental consequences Precautions All users must follow the safety Instructions given by the manufacturer and the Instructions of the person responsible for the product iCONgrade Safety Directions 63 iCONgrade Safety Directions 64 A caution AN Danger A Warning A Warning Watch out for erroneous measurement results if the product has been dropped or has been misused modified stored for long periods or trans
21. erence string curb or previous pass the best performance will be achieved when the sensor is positioned square to the reference not turned or leaning Setup over a curb When setting the Tri Sonic sensor over a curb it is generally recommended to use the GROUND mode and use the flat surface of the gutter as the reference as shown here Setup over an EDGE Use of the curb edge as a reference requires extra care be taken to ensure a proper distance and control of iCP32 system Unlike a string or a flat surface a curb edge can present some special problems It is best that this mode be used only by experienced operators Over any reference It is important to rotate and roll the blade of the Grader to its approximate working position before setting and adjusting the Tri Sonic sensor the blade edge and the reference 2 4 3 Set up and operation Level 1 Se Level 2 iCONgrade Operation Swap Function The swap function allows the operator to quickly and easily swap sensors turn the machine around and grade in the opposite direction by following the previously pass There are two levels to the swap function available Level 1 Swap the cross slope by inversing the actual target cross slope For example 2 3 gt 2 3 Level 2 Swap the cross slope by inversing the actual target cross slope and swap the side of the Grader that is controlled by ultrasonic By pressing F2 SWAP the actual target slope will
22. faces MJB1300 Battery MIL Cradle M12 Valves M12 CAN A MIL CAN B MIL CAN A M12 Interfaces MJB1301 Special feature for MJB1301 Battery MIL Cradle M12 Valves 2x M12 CAN A 2x MIL CAN B 2x MIL CAN A M12 Aux M12 Integrated main fall sensor 75 iCONgrade Technical Data MUS1300 Tri Sonic MPM700 Electric Mast MM4 Manual Mast 76 Parameter Specification Dimensions 17 2 x 18 3 x 14 cm Weight 2 5 kg Accuracy within 0 125 cm 30 5 cm Input voltage 11 to 30 VDC Power Consumption 0 5 A max Parameter Specification Voltage range 24 V DC nom Nominal voltage 24 V DC Range 10 V 30 V Power consumption lt 2 5A Mast height extended 2 9m Mast height retracted 1 7 m Mast travel 1 2 m Mast travel speed 85 mm per second Positions repeatability 1 mm Weight 30 kg Parameter Specification Height extended 3 257 m Height retracted 1 857 m MLS700 Laser Receiver iCONgrade Technical Data Parameter Specification Travel 1 4m Scale Metric Inch Weight 14 kg Parameter Specification Voltage range Power consumption 24 V DC nom Nominal voltage 24 V DC Range 11 V 30 V lt 500 mA Dimensions 28 x 12 x 7 2 cm without mounting bracket Weight 2 5 kg incl camp Detection angle 360 Linear detection height 190 mm Operating range
23. for height and lateral motion This will enable setting up of the Tri Sonic over any reference The support may differ according to the machine and reference In case of large differences in temperature between the storage and working environments allow 30 minutes for the sensor to adapt to the working environment prior to operation While ground and curb scanning the Tri Sonic should move longitudinally for the averaging of the scanned values For Stringline and Edge the Tri Sonic should be placed at an angle of 90 to the reference with the face plate orientated to back of the machine a Working direction b stringline Stringline and Edge For stringline sensing the Tri Sonic must be positioned across the reference wire The Auto sensing matic Side Shift control of the Tri Sonic will keep the sensor always over the reference using the hydraulics of the third valve section to regulate the Blade in and out Mounting the Tri Sonic Normal operation on the support 1 Release the clamping screw on the support 2 Insert the round centering pivot on the top of the sensor housing vertically into the support 3 Rotate the sensor to the required sensing mode refer to previous page 4 Lock the centering pivot of the sensor with the clamping screw Edge operation For sensing Edges it is required to tilt the sensor toward the Edge as shown on the picture Slacken the
24. g a Grader s blade cushioning device at the same time as the blade is being automatically controlled by the system results in poor automatic control performance Make sure that blade cushioning if installed is turned off before working with automatic controls 21 iCONgrade Operation 2 1 5 Dozer blade rotation 22 No blade rotation on Dozer For Dozer systems that use a cross slope sensor you must make sure that the blade is square to the machine not rotated Dozer blade square Dozer blade rotated Operating with a rotated blade can cause inaccuracy in the cross slope being cut When driving on a surface that has 0 cross slope and 0 long slope the blade can be rotated freely The bigger cross slope and long slope you are working with the bigger the error on a rotated blade will be 2 2 Sensor selection iCONgrade Operation Select the Input Source 1 Push the left or right key to open the sensor selection menu Following screen appears 23 iCONgrade Operation 24 2 Use the A Lv keys to scroll through the available sensors a If the sensor is connected and active it will show up in black b If it s not connected or inactive it will show in red ELO 1 04 0 2 Seek Swap SSAM Seek 3 Highlight the sensor that is going to be used and exit the sensor selection menu by pressing Z or 4 The chosen sensor is indicated by a small icon in the upper
25. he system is powered up please check the state of the machine to make sure that it is configured to function correctly Check and set When To learn how see Mast perpendicular to wheelbase For Graders without mast slope sensor and for Dozers every time the blade changes attack angle pitch 2 1 2 Mast orientation No articulation and circle side shift on Grader Every time a Job is to be made with a single eleva tion sensor cross slope sensor on a Grader 2 1 3 No Articulation circle center shift or wheel lean on Grader Turn Grader blade cushioning off Every time you want to use automatic controls on a Grader 2 1 4 Grader blade cush ioning off Dozer blade square Every time you begin a job with a single elevation sensor cross slope sensor on a Dozer 2 1 5 No blade rotation on Dozer 2 1 1 Hint for best performance iCONgrade Operation Best operation practice for Grader Systems Below you will find a list of things that will help achieve the best results when operating a Grader system e Ensure that mast is perpendicular to the wheelbase or use a mast slope sensor e Keep the circle centered under the gooseneck e Do not lean the wheels e Do not articulate the machine e Where possible move the machine in one direction only do not turn around e Where possible set the blade rotation and leave it in the same position e
26. iCONgrade Operation If any sensors are not installed or not connected a warning screen will appear Warning Rotation sensor not present Exit Skip Next Park the machine on a flat hard and level surface preferably a paved road or similar This will facilitate turning the machine around and proper machine alignment If the machine is already aligned properly and is ready for calibration skip ahead by pressing Skip F2 To start select Next Bee Back Skip Next 49 iCONgrade Operation Sensor Calibration 3 step Sensor Calibration 4 step 50 Straighten the machine s front wheels and articulation This ensures correct values for calibrating the mainfall sensor Select Next when complete sh a Back Skip Next Centre the machine link bar It must then be set in its centred position for proper Cross Slope calibration Select Next when complete hot MTT Back Skip Next Centre the Blade Sideshift ensuring the distance from the machine base to the blade tip is the same on both sides This is important for the measurements in the next step Select Next when complete Sensor Calibration 5 step B A e G Back Skip Next Rotate the blade so that the distance from the swivel to each blade tip is the same This ensures that the blade is perfectly perpendicular to the axis along the machine This is important for the c
27. ine Setups 55 3 Care and Transport 58 3 1 General Notices 58 3 2 Transport 58 3 3 Storage 58 3 4 Cleaning and Drying 59 4 Safety Directions 60 4 1 General 60 4 2 Intended Use 60 4 3 Limits of Use 61 4 4 Responsibilities 61 4 5 Hazards of Use 62 4 6 Electromagnetic Compatibility EMC 66 4 7 Labelling 68 5 Technical Data 74 5 1 iCP32 Technical Data 74 5 2 Conformity to National Regulations 81 6 International Limited Warranty Software License Agreement 82 iCONgrade Table of Contents 5 iCONgrade Product Overview 1 1 1 General Power supply commu nication Product Overview Product Description and Features The control panel has keys surrounding the screen for user input The 3 5 colour display incorporates a state of the art LCD colour screen making it easy to use even in bright sunny conditions The rugged IP56 enclosure is designed for harsh environments The control panel is powered from a cradle based on a sophisticated induction solution while data is transferred wirelessly via infrared between the MMB1300 cradle and the iCP32 control panel The MMB1300 will be called the Cradle throughout this manual iCP32 control panel a cH c iCP32_001 e f g a Graphical display e Menu key b Grade indication LEDs f Function keys c Left Right side sensor setup g Enter key d Speaker A Warning This product may be installed on building machinery on
28. laser beam lost To use the Laser Sensor with a manual mast for controlling the elevation of the blade complete the following steps 1 Select the Laser Sensor on one of the sides 2 Place the cutting edge of the blade at the desired height 3 Move the mast up or down until the Laser Sensor detects the laser beam Continue to move the mast until the indication led s on the Laser Sensor is showing a green line 4 Press the left key to set the machine in Auto Mode 5 When the control panel is in Auto Mode the machine will start to move the raise lower hydraulic cylinders so that the laser beam always is in the center of the Laser Sensor 39 iCONgrade Operation 40 Laser Sensor and To use the Laser Sensor with a power mast for controlling the elevation of the blade MPM700 Electric Mast complete the following steps 1 2 Place the cutting edge of the blade at the wanted height 3 4 Press the or key to tell the mast in which direction it should start to seek The Select the Laser Sensor in one of the sides Enter SEEK mode mast will now move in the given direction until the Laser Sensor detects the laser beam and has it in the center of the sensor 5 Press the left 24 key to set the machine in Auto Mode y The and keys can now be used to move the mast up or down and thereby changing the elevation reference 2 6 Introduction er er Enabling the SP14 Sensor iCONgrade Operation SP14 Se
29. librated values and exit the wizard by pressing Save To exiting the wizard without saving press Exit Calibration complete Save Exit 54 2 10 Grader Setup iCONgrade Operation Machine Setups iCP32 Control panel MMB1300 Cradle External Multi Switch Cross slope sensor Rotation sensor Laser receiver MPM700 Electric Mast manual mast Sonic Tracker MJB1301 Junction box Grader Hydraulic valve Machine battery 55 iCONgrade Operation Dozer Setup a b c d e f h i j k 56 iCP32 Control panel MMB1300 Cradle External Switch for Dozer Laser receiver MPM700 Electric Mast manual mast MJB1300 Junction box Dozer Machine battery Hydraulic valve Cross slope sensor or SP14 Sensor Remote junction box Remote display iCONgrade Operation 57 iCONgrade Care and Transport 58 3 3 1 General information Periodic checks 3 2 Transport in the field Transport in a road vehicle Shipping 3 3 Product Care and Transport General Notices Servicing the system only requires a minimum of time All electronic components are enclosed in robust housings to safeguard them against mechanical damage If any iCP32 components are subjected to severe impact be sure to check for proper oper ation prior to performing any work with the system Transport When transporting the equipment in the field alwa
30. ly by an appropriately trained and qualified specialist iCONgrade Product Overview iCONgrade Product Overview 8 A Warning Unauthorized modification of machines by mounting the product may alter the function and safety of the machine Precautions Follow the instructions of the machine manufacturer If no appropriate instruction is avail able ask the machine manufacturer for instructions before mounting the product Keys Up key Down key Enter key Auto Manual key Menu key MENU Sensor select key Gy Fuction keys 2 as Ti N TI w T K Display iS a i E 3 FEG a Side shirt neni indication b Above grade c Left Right on grade indication d Below grade iCONgrade Product Overview iCONgrade Product Overview MMB1300 Cradle icP32_003 a Power and data transfer LED indicators b Holding magnets c On off switch d Release key for control panel 10 1 2 Getting Started System start To get the system started complete the following steps 1 Snap control panel onto cradle To connect the control panel to the cradle 1 Put the control panel on the holding hooks in the bottom of the cradle 2 Then snap the control panel onto the cradle by pressing it towards the cradle icP32_004 iCONgrade Product Overview 11 iCONgrade Product Overview 12 2 Turn on the control panel To turn the sys
31. national Limited Warranty Software Licence Agreement This product is subject to the terms and conditions set out in the International Limited Warranty which you can download from the Leica Geosystems home page at http www leica geosystems com internationalwarranty or collect from your Leica Geosystems distributor The foregoing warranty is exclusive and is in lieu of all other warranties terms or conditions express or implied either in fact or by operation of law statutory or otherwise including warranties terms or conditions of merchantability fitness for a particular purpose satisfac tory quality and non infringement all of which are expressly disclaimed This product contains software that is preinstalled on the product or that is supplied to you ona data carrier medium or that can be downloaded by you online pursuant to prior author isation from Leica Geosystems Such software is protected by copyright and other laws and its use is defined and regulated by the Leica Geosystems Software License Agreement which covers aspects such as but not limited to Scope of the License Warranty Intellectual Property Rights Limitation of Liability Exclusion of other Assurances Governing Law and Place of Jurisdiction Please make sure that at any time you fully comply with the terms and conditions of the Leica Geosystems Software License Agreement Such agreement is provided together with all products and can also be referred to an
32. nsor The SP sensor is a new technology in machine automation It improves smoothness obtained with GPS PowerTracker and laser reference sensors In addition the dozer can be operated with increased speed compared to a system without SP technology The SP Technology can only be used on Dozers with the Control Box iCP42 together with PowerBox or PowerTracker The SP Technology MUST be turned off when using the SP14 sensor together with a laser or sonic sensor If the system is equipped with a SP sensor it is recommended to have it enabled at all times SP functionality can be enabled or disabled in the tech mode SP Main gt Sensor config gt SP14 config ESC 41 iCONgrade Operation Benefits from using the SP14 Sensor 42 For a system with GPS SP technology results in greater smoothness increased operation speed and a system that is more robust against poor GPS coverage For a system with PowerTracker SP technology results in greater smoothness increased operation speed and a system that is more robust against losing the prism in case of the beam being interrupted 2 7 How to set 3D sensor type iCONgrade Operation 3D Sensors Select 3D Height press the left or right sensor key once and then press the Adjust function key to enter the adjust menu Note that it s only the current selected sensor in either left or right side that is adjusted If the 3D system is configured to indi
33. ons 70 Labelling MLS700 Laser Receiver TYPE MLS700 P N 760862 feica Leica Geosystems AG CH 9435 Heerbrugg Made in Denmark 20XX S N XXXXXXXX C X Power 12 24 V DC 6A max icP32_010 Labelling MPM700 Power Mast TYPE MPM700 P N 760863 S N XXXXXXXX icP32 011 e Sica Leica Geosystems AG CH 9435 Heerbrugg Made in Denmark 20XX CE Power 12 24 V DC 6A max iCONgrade Safety Directions 71 iCONgrade Safety Directions Labelling MUS1300 Tri Sonic N Tri Sonic icP32_012 72 Art No Type MUS1300 764031 Power 11 30V 0 5A max S No Leica Geosystems AG CH 9435 Heerbrugg Manufactured 2010 Made in Switzerland Patents U S 5 327 345 4 733 355 This device complies with part 15 of the FCC Rules Operation is subject to the following two conditions 1 This device may not cause harmful interference and 2 this device must accept any interferences received including interference that may cause undesired operation Labelling MRS1300 Rotation Sensor icP32_013 TYPE MRS1300 S N XXXXXXXX 12 24 V DC 6A max Leica Geosystems AG CH 9435 Heerbrugg Made in Denmark 20XX Labelling MSS1300 Cross Slope Sensor icP32_014 TYPE MSS1300 P N 764842 S N XXXXXXXX feica Leica Geosystems AG CH 9435 Heerbrugg Made in Denmark 20XX CE K Power 12 24 V DC 6
34. orrect calibration of the rotation sensor Select Next when complete a G Sensor Calibration 6 step Back Skip Next iCONgrade Operation 51 iCONgrade Operation 52 Sensor Calibration Mark the positions of the wheels on the ground and place the blade gently on solid blocks 7 step or other solid reference ensure the blade has not rotated or sideshift has been altered Select Next when complete a Back Skip Next Sensor Calibration The rotation sensor will automatically calibrate while at the same time collecting Mainfall 8 step and Cross Slope data Select Next when complete Calibrating Rotation Sensor E Back Skip Next Sensor Calibration 9 step Sensor Calibration 10 step iCONgrade Operation Turn the machine around and place the blade gently on the same blocks or reference as before ensuring that the blade is not rotated or sideshift has altered Align the wheels using the markings from the previous step This is important for the correct measure ment of the Mainfall and Cross Slope values Select Next when complete Back Skip Next The Mainfall and Cross Slope sensors will now be automatically calibrated Select Next when complete Calibrating Mainfall amp Slope Sensors Si 26 Save Exit 53 iCONgrade Operation Sensor Calibration The calibration routine is complete 11 step Save the ca
35. ose safety concepts in combination with the Leica Geosystems product ue person in charge of the product has the following duties To understand the safety instructions on the product and the instructions in the user manual e To be familiar with local regulations relating to safety and accident prevention e To inform Leica Geosystems immediately if the product and the application becomes unsafe The person responsible for the product must ensure that it is used in accordance with the instructions This person is also accountable for the training and the deployment of personnel who use the product and for the safety of the equipment in use Unauthorized modification of machines by mounting the product may alter the function and safety of the machine Precautions Follow the instructions of the machine manufacturer If no appropriate instruction is avail able ask machine manufacturer for instructions before mounting the product This product may be installed on building machinery only by an appropriately trained and qualified specialist Hazards of Use Only Leica Geosystems authorised service workshops are entitled to repair these products A caution A Warning A Warning A Warning Installing near mechanically moving machine components may damage the product Precautions Deflect the mechanically moving machine components as far as possible and define a safe installation zone Beware of inadequat
36. ported Precautions Periodically carry out test measurements and perform the field adjustments indicated in the user manual particularly after the product has been subjected to abnormal use and before and after important operations Because of the risk of electrocution it is very dangerous to use poles and extensions in the vicinity of electrical installations such as power cables or electrical railways Precautions Keep at a safe distance from electrical installations If it is essential to work in this environ ment first contact the safety authorities responsible for the electrical installations and follow their instructions During dynamic applications there is a danger of accidents occurring if the user does not pay attention to the environmental conditions around for example obstacles excavations or traffic Precautions The person responsible for the product must make all users fully aware of the existing dangers Inadequate securing of the work site can lead to dangerous situations for example in traffic on building sites and at industrial installations Precautions Always ensure that the work site is adequately secured Adhere to the regulations governing safety and accident prevention and road traffic A caution If the accessories used with the product are not properly secured and the product is subjected to mechanical shock for example blows or falling the product may be damaged or people may sust
37. t the blade should move 8 cm for a laser sensor controlling tilt Laser 8 cm 2D and 3D cross slope sensor This should be measured 1 5 meters from the centre of the blade Press the Test button to adjust the value so that it corresponds to the below distances For example during 2 seconds of movement the blade should move 8 cm for 3D cross slope on Dozer Sensor Dozer Grader 2D and 3D cross slope 8 cm 14 cm Sideshift Grader only Enter the Tri Sonic or 3D height adjust menu Press the Test button to adjust the value so that it corresponds to the below distances 2D and 3D sideshift 13 cm iCONgrade Operation 47 iCONgrade Operation 48 2 9 Sensor Calibration Wizard Enter the Sensor In order to maintain the correct calibration of the sensors the Sensor Calibration Wizard Calibration Wizard should be run periodically due to blade wear This should also be done when changing the blade wear edges or changing tires on a grader as this will change the mainfall slope This is done by entering the calibration wizard Menu gt Calibration gt Sensor Calibration and following the on screen instructions Sensor Calibration Select the Sensor Calibration Follow the on screen instructions to calibrate each sensor 1 step The following example is for graders but the dozer sensor calibration is similar Sa a EG Ea Main gt Calibration Warning Screen Sensor Calibration 2 step
38. tem on and off use the power switch on the right side of the cradle This is the master switch for the entire system CS Removing the panel will also turn off the power icP32_005 CS To release the control panel simply press the release key at the bottom of the cradle and pull the control panel towards you and then lift it up icP32_006 1 3 Sensor Setup Keys Sensor setup keys The sensor setup keys are used to choose the type of sensor that the system should run with and to find and set the reference point for that sensor The left and right hydraulic channel has four sensor setup keys each e Auto Manual key e up key 1 down key sensor select key External Multi Switch for Grader The system can also be fitted with an External Multi Switch This switch has three keys on it One Auto Manual key Red and a set of up and down keys green These keys have the same function as the corresponding keys on the control panel iCONgrade Product Overview 13 iCONgrade Product Overview 14 Toggle the master switch to AUTO to enable automatic control on all chan nels selected on the control panel Toggling the master switch to MAN places all channels in manual control regardless of selection on the control panel External switch for Dozer iCONgrade Product Overview 15 iCONgrade Operation 2 2 1 State of the machine Operation Pre power up checks 16 Before t
39. u key The deadband controls the precise motion of machine hydraulics These values do not corre spond to accuracy but only to hydraulic speeds These values should not be confused with overall machine performance and or precision The automatic hydraulic calibration will set the dead band values and these should NOT be changed Default values Sensor Dozer Grader GPS 1 0 cm 1 0 cm Laser 0 7 cm 0 7 cm Cross slope 0 6 0 3 Tracker 0 5 cm 0 5 cm Sideshift ans 2 0 cm 45 iCONgrade Operation Gain 46 This is the scaling of hydraulic speeds for each of the sensors To enter Gains select the Lower Left or Lower Right buttons to open up the available sensors Select appropriate sensor and then the or key depending on left or right side to enter the Adjust Menu The automatic hydraulic calibration will calculate the optimal gain values It is recommended not to change these values Elevation Press the Test button to adjust the value so that it corresponds to the below distances For example during 2 seconds of movement the blade should move 13 cm for GPS Sensor Dozer Grader Laser Sonics Tri Sonics GPS 13 cm 13 cm Tracker 7 cm 7 cm Second laser for cross slope This should be measured 1 5 meters from the centre of the blade Press the Test button to adjust the value so that it corresponds to the below distances For example during 2 seconds of movemen
40. ys make sure that you carry the product in its original transport container Never carry the product loose in a road vehicle as it can be affected by shock and vibration Always carry the product in its transport container and secure it When transporting the product by rail air or sea always use the complete original Leica Geosystems packaging transport container and cardboard box or its equivalent to protect against shock and vibration Storage Respect the temperature limits when storing the equipment particularly in summer if the equipment is inside a vehicle Refer to Technical Data for information about temperature limits 3 4 Cleaning and Drying Product e Blow off dust e Use a clean soft lint free cloth for cleaning If necessary moisten the cloth with water or pure alcohol Do not use other liquids these may attack the polymer components Cables and Plugs Keep plugs clean and dry Blow away any dirt lodged in the plugs of the connecting cables Damp products Dry the products at a temperature not greater than 40 C 108 F and clean them Do not repack until everything is completely dry iCONgrade Care and Transport 59 iCONgrade Safety Directions 60 4 4 1 Description 4 2 Permitted use Adverse use Safety Directions General The following Instructions should enable the person responsible for the product and the person who actually uses the equipment to anti
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